Folded package and method of formation

ABSTRACT

The technology described herein generally relates to particular form of folded package and the method of forming that folded package. More particularly, using a folding tip and the application of vacuum pressure to a paper cone it is possible to achieve the formation of properly folded packages that may further include a core that is deposited axially along the length of the package.

INCORPORATION BY REFERENCE

This application claims priority to and incorporates by reference intheir entirety and for all purposes each of U.S. Provisional PatentApplication Ser. No. 62/662,918 filed on behalf of Mark W. Holderman andGregory August Russell, U.S. Provisional Patent Application Ser. No.62/783,394 filed on behalf of Mark W. Holderman and Gregory AugustRussell, PCT/US19/26711 filed on behalf of Mark W. Holderman and GregoryAugust Russell, U.S. patent application Ser. No. 16/380,194 (now U.S.Pat. No. 11,130,596) filed on behalf of Mark W. Holderman and GregoryAugust Russell, U.S. patent application Ser. No. 17/402,076 (now U.S.Pat. No. 11,485,523) filed on behalf of Mark W. Holderman and GregoryAugust Russell, and U.S. patent application Ser. No. 17/949,288 (nowU.S. Pat. No. 11,485,523) filed on behalf of Mark W. Holderman andGregory August Russell.

BACKGROUND

Prior to the development of the present apparatus and system, papercones were filled by hand. People would individually stuff product, suchas leaves, into a single cone, and mechanically tamp down the leaves.Alternately, numerous cones could be placed in what is essentially ahoneycomb structure with holes that accommodate the cones. Crumbledleaves were then scattered over the holes containing the cones andvibrations or mechanical tamping was used to pack the leaves into thecones.

Each of the foregoing resulted in inaccurate and non-uniformly filledcones. The mechanical tamping often left the leaves too compacted.Sometimes the leaves at the bottom of the cone would be packed too much,while the leaves toward the top of the cone would remain too loose. Themechanical pressure had a tendency to rip the paper cones. Simplyrelying on vibrations to fill the cones would often result in leavesthat were too loose.

These problems were often compounded by the type of plant matter used.Specifically, for plant matter containing a relatively high oil content,the crumbled leaves tended to exhibit a sticky quality that resulted inclumping of the leaves together. The clumped leaves negatively affectedthe utility of the vibration method because the vibrations alone werenot sufficient to break up the clumps. Similarly, the tamping methodsimply resulted in clumps that were more tightly packed together,exacerbating the problem. In both cases, the clumps tended to lodge inthe narrow part of the cone creating air gaps or otherwise non-uniformpacking of the plant material within the cone.

Non-uniform packing creates a number of problems. For example, it canaffect the weight of the final product. When clumps get packed in withmore loose plant matter, the density of the clumps can result in morethan the desired amount of plant matter being packed into the cone. Theclumps tend to burn at a different rate, disrupting the natural andcorrect burn rate of a correctly and uniformly packed cone. When clumpscreate air-gaps, the burn rate of the plant matter can be negativelyaffected because the lack of solid contact among the plant matter canresult in an extinguishing of the plant matter. The density of theclumps can disrupt the flow of air through the plant matter, and actlike a blockage in a straw.

Filling cones by hand, or with the honeycomb type packing device alsonecessitates closing each of the cones by hand. Using those methods, aperson was required to manually manipulate each cone and fold the openend to seal in the plant material and prevent it from falling out. Oftenthe cones would simply be closed by twisting the paper on top of thecone together to completely close and seal the top of the cone. Thatmanual process is taxing on a person's hands and limits the number ofcones that can be filled in a given amount of time. It also tends toresult in non-uniform folds/twisted closures as people tend to havedifferent techniques for folding/twisting and dexterity becomes morelimited as hands and fingers become more fatigued.

SUMMARY

The present system provides an apparatus that accurately and uniformlyfills paper cones with loose particles and closes the cones to preventthe particles from escaping the cones. While embodiments may generallybe described herein as filling the cones with crumbled plant matter,such as crumbled dried leaves, it should be understood that any looseparticles that could fit within the cone could be used as a filling forthe cone without departing from the general scope of the apparatus andsystem. For simplicity, all such loose particles will simply be referredto herein as “leaves,” but the use of that term herein in no way limitsthe apparatus to only packaging organic plant matter. It should beunderstood that while “paper” is a common substance to be used forcones, that term is used generically herein for any relatively thin,flexile, flammable substrate and is not strictly limited to traditionalpaper. It should be understood that the term “cone” need not be atraditional cone with a point at one end, but may be of any generallycylindrical shape or shape having a greater length than width (ordiameter, where the term “width” as it is used in describing the widthof an object having a circular cross section is the diameter), thoughpreferably the shape of a truncated traditional cone.

The present apparatus and system overcome the shortcomings of thepreviously described manual methods by ensuring that the leaves areuniformly and consistently packed into the cones. The process isautomated, allowing for consistent packaging and uniformity in the finalproduct. It expedites the overall process of packing the cones. Thepresent apparatus and system includes a number of sub-components thatindividually perform packing functions. The sub-components eachindividually overcome different problems that occur when manuallypackaging leaves in cones. For example, an embodiment of the presentapparatus and system includes a leaf hopper and trough conveyor. Itprecisely measures units of leaves for packaging, breaks up clumpedleaves initially and prevents clumping of the leaves as the leaves aretransferred through the apparatus. A conveyor, such as a carousel,manages the flow of cones into the system. It holds large quantities ofcones and moves them into the precise position for packaging whilepreventing undesirable crimping and folding of the cone that couldotherwise affect the quality of the finished, packed cone.

Another sub-component is the packing sub-assembly. It includes a hopperthat feeds leaves into the cone. A combination of vibrations andsuccessive applications of pulsed air may be used to ensure evendistribution and uniform packing of leaves in the cone. A vacuum systemis further connected to remove any stray leaves that failed to properlybe packed into the cone and thereby prevents unnecessary buildup andwaste of leaves.

A folder sub-component and injector sub-component (which in someembodiments are incorporated into a single sub-component while in otherembodiments are arranged as separate sub-components) complete thepackaging of the cone. The folder sub-component properly orients thecone. Folding fingers precisely bend a portion of the cone and a foldingtip compresses the bent portion of the cone to close it. Depending onthe product being packaged into the cones, it may be advantageous toinject a further substance, such as oil, into to the packed cone. Insome instances the oil may be derived from the same family of productthat is being packed into the cone, such as an oil derived from the sameplant family as the leaves that are used to fill the cone. In suchinstances, after compressing the cone with the folding tip, an injectorneedle penetrates the cone and is withdrawn, leaving a deposit of thefurther substance through the leaves in the cone as the needle iswithdrawn. This creates a line, or core, of the further substancethrough the leaf filled cone.

In one embodiment, after completing the folding, and if desiredinjecting, steps, the packaged cone is transferred to a quality controlstation. The quality control station checks to ensure the packaged conemeet the necessary quality parameters, for example, weight, shape, andcolor. Passing cones are transferred to an appropriate receptacle, whilefailing cones are rejected. Injecting could also be accomplishedseparately and after inspection.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of an embodiment of the apparatus andsystem depicting the relationship between various sub-systems of theapparatus.

FIG. 1B is a perspective view of an alternative embodiment of theapparatus and system depicting the relationship between the varioussub-systems of the apparatus.

FIG. 2A is a perspective view of an embodiment of the carousel.

FIG. 2B is a close-up plan view of a portion of one embodiment of aplate of the carousel exhibiting a geometric hole.

FIG. 2C is a perspective view of an embodiment of a cone.

FIG. 3A is a perspective view of an embodiment of the carousel inrelation to an embodiment of de-nesting fingers and an embodiment of acone conveyor.

FIG. 3B is a close-up perspective view of an embodiment of de-nestingfingers in a closed position.

FIG. 3C is an exploded view of an embodiment of de-nesting fingers.

FIG. 3D is a side view of embodiments of a cone conveyor and dies.

FIG. 3E is a perspective view of embodiments of a cone conveyor anddies.

FIG. 3F is an exploded view of an embodiment of a die.

FIG. 3G is a perspective view of an embodiment of a die.

FIG. 4A is a side view of embodiments of a hopper and conveyor.

FIG. 4B is an alternative side view of embodiments of a hopper andconveyor.

FIG. 4C is a perspective view of embodiments of a hopper and conveyor.

FIG. 4D is a close-up side view of an embodiment of a hopper andconveyor depicting a portion of the hopper within the conveyor alongwith a damper plate within the conveyor.

FIG. 4E is a perspective view of an embodiment of a grinder hopper andwheel.

FIG. 4F is an alternative perspective view of an embodiment of a grinderhopper and wheel.

FIG. 5A is a perspective view of an embodiment of a packing station.

FIG. 5B is a perspective view of an embodiment of a packer head.

FIG. 5C is an alternative perspective view of an embodiment of a packerhead.

FIG. 5D is an exploded view of an embodiment of a packer head.

FIG. 5E is a perspective view of an embodiment of a weigh station in aclosed position.

FIG. 5F is an alternative perspective view of an embodiment of a weighstation.

FIG. 5G is an exploded perspective view of an embodiment of a conesupport system.

FIG. 5H is a side view of an embodiment of a cone support systemoriented in relation to an embodiment of a cone conveyor.

FIG. 5I is a perspective view of an embodiment of a cone support systemoriented in relation to an embodiment of a cone conveyor.

FIG. 6A is a perspective view of an embodiment of a folder station.

FIG. 6B is an exploded view of an embodiment of folder fingers.

FIG. 6C is a partially exploded perspective view of an embodiment of aportion of a folder station including an injector needle.

FIG. 6D is a cross-sectional side view of an embodiment of a folderstation including an injector needle with an unfolded cone.

FIG. 6E is a cross-sectional side view of an embodiment of a folderstation including an injector needle with a partially folded cone.

FIG. 6F is a cross-sectional view of an embodiment of a folder stationwith injector needle inserted into a cone.

FIG. 6G is a cross-sectional view of an embodiment of a folder stationwith injector needle extracted from a cone and a cone having a fluidcore.

FIG. 6H is a close-up plan view of an embodiment of folder fingers in apartially closed state.

FIG. 6I is a close-up plan view of an embodiment of folder fingers in aclosed state.

FIG. 6J is a side view of an embodiment of folder fingers in an openstate.

FIG. 6K is a plan view of an embodiment of folder fingers in an openstate.

FIG. 6L is a perspective view of an embodiment of a folder tip with anaxial pin.

FIG. 6M is a plan view of an embodiment of a folder tip with an axialpin.

FIG. 6N is a cross-sectional side view of an embodiment of a folder tipwith an axial pin.

FIG. 6O is a perspective view of an embodiment of a cone folded by anembodiment of the folder tip with an axial pin.

FIG. 6P is a cross-sectional side view of a distal end of an embodimentof a filled cone with a fluid core folded by an embodiment of the foldertip with an axial pin.

FIG. 7A is a side view of an embodiment of a fluid injector station.

FIG. 7B is a perspective view of an embodiment of a fluid injectorstation.

FIG. 7C is a cross-sectional side view of an embodiment of a fluidinjector station.

FIG. 7D is a perspective view of an embodiment of an injector stationand gas purge packaging station.

FIG. 8 is a perspective view of an embodiment of a quality controlstation.

FIG. 9 is a flowchart describing the operation of an embodiment of thepackaging assembly.

FIG. 10 is a schematic of an embodiment of a control system inconnection with a plurality of actuators and sensors.

DETAILED DESCRIPTION OF EMBODIMENTS

Throughout the specification, wherever practicable, like structures willbe identified by like reference numbers. In some figures, components,such as additional electrical connections and tubing (such as vacuumtubing and pneumatic tubing) have been omitted for clarity in thedrawings. Additionally, in some figures repetitive structures, such asmultiple actuators have been omitted. In such cases exemplary componentsare provided for explanatory purposes and it should be understood thatother similar devices in the drawings may be provided with similarcomponents. Unless expressly stated otherwise, the term “or” means“either or both” such that “A or B” includes A alone, B alone, and bothA and B together.

FIG. 1A and FIG. 1B generally depict embodiments of a packaging assembly100. Embodiments may include a carousel 200, a cone conveyor 300, ahopper assembly 400, a leaf conveyor 407, a grinder hopper 401, apacking station 500, a weigh station 510, a folder station 600, and aquality control station 800. Additionally, the packaging assembly mayinclude a conveyor 806, and an injector station 700 (which may beintegrated with the folder station or a separate station). The variouscomponents may be mounted to a table 101.

The packaging assembly is also equipped with a number of actuators. Theactuators move the various components of the assembly into their properpositions. In one embodiment, the actuators are generally pneumaticactuators and electric motors, though it should be appreciated by one ofordinary skill in the art that any actuator could be used. By way ofnon-limiting example, continuous speed motors, variable speed motors,servo motors, hydraulics, or magnetic actuators could be used. By way offurther example, an actuator could be in the form of a simple valve orswitch that the control system operates to permit a hydraulic orpneumatic fluid to flow through the system and provide the forcerequired by the system. A vacuum pump and vacuum tubing may also beutilized to control airflow in the system.

An electrical control system (one embodiment of which is described infurther detail with respect to FIG. 10 ) is used to monitor and controlthe operation of the system and packaging assembly. The electricalcontrol system may include dedicated circuits, programmable computerhardware, firmware, software, controllers, or a combination thereof. Thecontrol system coordinates the operation of the apparatus and system andparticularly coordinates the actuators and the vacuum as well asutilizing sensor data, preset parameters stored in the control system,or a combination thereof. While it generally is advantageous to utilizea control system of a self-contained, locally oriented computer (withaccompanying input and output devices such as a display, keyboard,mouse, touch screen, voice command control, etc.) to reduce latency inthe feedback and command loop between the sensors, computer, andactuators, it is contemplated that parts of the control system could beorganized in a distributed manner, with sub-control systems operatingportions of the packaging system while networked with a main computercontroller, or even that portions of the control system could be locatedoff-site and connected over the internet.

In one embodiment, a computer monitors the sensors of the packagingassembly, and coordinates the operation of the actuators of thepackaging assembly. Simultaneously, the computer records data respectingthe operation of the packaging assembly. For example, the computerrecords the time each actuator is activated. The computer system mayfurther compile the number of operations of each actuator to determinewhether a completed product should have been created. For example, thecomputer identifies that the actuators of the carousel were activated,followed by the activation of the de-nesting fingers. A feedback sensoron the de-nesting fingers informs the computer that a cone wassuccessfully withdrawn from the carousel and the computer logs thatdata. The computer then records activation of the cone conveyor and theactivation of a weigh station sensor and weigh station actuator(indicating that product has been fed to the cone). The computer systemlogs the activation of the packing rod actuator followed by theactivation of folding finger actuators (indicating that the filled conehas been completed), the computer then logs the die actuator (releasingthe filled cone) followed by sensor feedback from quality controlsensors (such as recording the weight of the cone, an image of the cone,or a simple check that the cone is present). The computer then recordswhether the reject actuator was activated to determine whether the conewas accepted or rejected. The computer records the subsequent activationof the actuators of the fluid injecting station, including the operationof the fluid pumps to record whether the cone was filled with a fluidcore, and how much fluid was deposited in the cone. Subsequent qualitycontrol data (and acceptance/rejection data) as described previously maybe recorded. In some embodiments the fluid filling occurs prior to anyquality control. By coordinating the recording of the data pertaining tothe actuators and sensors, the computer system is able to trackindividual cones as they progress through the packaging system.

When a cone is expected, but not present, the computer may log theinstance and generate an alert. For example, if all actuators andsensors are logged from the extraction of a cone from the carousel tothe folding station, the computer expects that a filled cone will nextbe present in the quality control station. If the die actuator activatesand no filled cone is sensed at the quality control station, thecomputer can generate an alert indicating that the expected filled coneis missing. In that way, the computer system can help prevent theft ofcompleted cones.

Also, the data can be used to assess the operation of the packagingassembly. The preferred timing of the actuators is known and stored inthe memory of the computer. As the computer gathers data, it comparesthe actual timing against the preset value for optimal timing. If theactual data is outside of a preferred range, the computer may adjust theactual timing of one or more of the actuators (for example, the computermay activate an actuator slightly earlier than previously to bring theactuator into the proper timing) or may generate an alert to have atechnician reset the operation of the assembly (or actuator). Thecontrol system may be connected to the internet such that data regardingthe operation of the actuators and sensors may also be transmitted to aremote computer for monitoring the operation of the assembly remotely.In one embodiment, when the computer compiles data regarding thecoordinated activation of the actuators and sensors indicating that acone has been filled and quality checked, the computer increments thenumber of cones filled (subtracting and logging the number of conesrejected). The computer system may then generate a report indicating thenumber of cones filled and accepted over a particular time period.

In general, the components are arranged to facilitate the movement of acone through the packaging system. In one embodiment, the cone conveyoris adapted to move the cones from station to station to effectuatefilling of the cones. For example, in the embodiment of FIG. 1A, whenthe conveyor is moved in the forward direction (which in FIG. 1Acorresponds to the counterclockwise direction, though it should beunderstood that “forward” simply means a direction that moves a point oncone conveyor from a starting point successively past stations of thepackaging apparatus before returning that point to the starting point),the cone conveyor moves a cone from the carousel to the packing station,then to the folding station, then to the quality control station beforereturning to the starting point of the carousel and receiving anothercone.

FIG. 2A generally depicts an embodiment of the carousel 200. It includesat least one plate. It should be appreciated that a “plate” could be ofany size and shape, and is not limited to a flat plate as shown in FIG.2A. Rather, a flat, generally circular plate (as shown) can effectivelyand economically convey the cones in the present system. In theembodiment shown, the carousel includes three plates 210, 220, 230arranged vertically along a support rod 240. The support rod isconnected to a rod actuator 250. The rod actuator 250 rotates thesupport rod and thereby rotates the carousel including plates 210, 220,230.

With reference to FIGS. 2A and 2B, each of the plates includes a seriesof holes located circumferentially along an outer perimeter (seegenerally, 280) of the plate. For example, in FIG. 2B, plate 230includes holes 231, 232, 233, 234, 235, 236, 237, and 238. Preferably,the holes of the upper two plates, 210 and 220, have diameters that arethe size of or slightly larger than the largest diameter of the cones1100. Thus, the cones may pass freely through the holes of those twoplates. In one embodiment, the holes of plate 230 have a diameter thatis less than the largest diameter of the cones, or have a geometricshape that results in frictional engagement of a cone placed in thehole. In one embodiment, the holes of plate 220 each include a holeactuator and a hole clamp (for explanatory purposes, only one holeactuator and hole clamp is depicted). As an example, FIG. 2A depictshole actuator 260 and hole clamp 270. The hole actuator actuates thehole clamp to apply and release pressure on the stack of cones such thatwhen pressure is applied, the cones are prevented from passing throughthe associated hole on plate 220. That assists in relieving the pressureon the cone that is frictionally engaged with the geometric hole 236 andprevents the weight of the cone stack 1100 a from prematurely pushingcones through the geometric hole. When pressure is released, the conesmay pass through the hole associated with the actuator and clamp onplate 220 under the weight of the stack of cones 1100 a. In oneembodiment the actuator 260 includes a piston 261 that connects to amovable clamp block 271. A fixed clamp block 272 is fixed to plate 220.The actuator 260 actuates the piston to slide the movable clamp block271 toward and away from the fixed clamp block 272 to apply or releasepressure on the cone stack 1100 a. Thus, the actuator moves the clamp tocreate and alleviate a restriction at the associated hole so as toprevent or allow cones to pass through the hole. It should beappreciated that alternative clamps could be used such as a constricting(or sphincter) clamp that encircles the cones such that the actuatorconstricts and releases the clamp to apply and release pressure on thecone stack.

Respecting the cones, cone 1100 of FIG. 2C is an example of a cone thatmay be packed using the present system. The cones are stacked in anested fashion in the carousel (see, generally, 1100 a). The conesexhibit a proximal end 1101 and a distal end 1102 that are locatedopposite one another and joined by a middle section. The cones arehollow such that air may enter the distal end, be drawn through thecone, and exit the proximal end. Preferably, the distal end exhibits adiameter that is larger than the diameter of proximal end.

Preferably, each of the holes 231, 232, 233, 234, 235, 236, 237, and 238on the bottom plate 230 is not circular. Rather, as shown in FIG. 2Bwhich depicts an exemplary hole 236 in an expanded view, the wall 239 ofeach hole each may include a geometric shape. As used herein,“geometric” means that the shape is not a circle. Preferably, thegeometric shape is an eight pointed star. The use of a hole with a wallhaving a geometric shape reduces the size of the hole so that it issmaller than the largest circumference of the cone. Thus, a cone willnot pass through the hole 236 under its own weight, but instead must beforced through. The preferred size of the geometric shape is onlyslightly smaller than the greatest circumference of the cone so that asthe cone is forced through the hole, the paper cone resiliently deformsand the geometric shape prevents plastic deformation of the cone, suchas a crease in the cone. In one embodiment, the geometric shape isformed in the plate by cutting a hole that has a geometric shape intothe plate. Alternately, a hole of any shape, including circular, couldbe cut into the plate and that hole could be filled with a material,such as a molded resin, plastic, or rubber, that surrounds the wall ofthe hole and that has an interior hole that is a geometric shape.

In one embodiment, the cone is extracted from the carousel 200 by beingpulled down through the geometric hole. An actuator activates, forexample, a clamp or a suction cup to temporarily attach to the cone andpull the cone from the carousel 200. It should be appreciated that analternative carousel in the form of a flexible conveyor, in place ofrigid plates, could be utilized to move stacks of cones into positionproximal to the cone conveyor so as to enable the transfer of cones fromthe carousel to the cone conveyor. It should be appreciated that whileone embodiment uses three plates, an alternate embodiment could use moreplates and more actuators to relieve the weight of taller stacks ofcones. Alternately, fewer plates could be used, and depending on theweight of the stack of cones, a simplified embodiment could eliminatethe use of actuators to relieve the weight of the stacks of cones.

FIG. 3A depicts an embodiment of the system including the positioning ofthe carousel 200, the cone conveyor 300, and de-nesting assembly 360.With reference to FIG. 3B, in one embodiment, the cone may be grasped byde-nesting fingers 361 and 362. One or more of the fingers are moved bya de-nesting actuator 363 to open and close the fingers and are alsomoved by a vertical actuator 364 to adjust the vertical position of thede-nesting fingers with respect to the cone conveyor 300.

FIG. 3B is a depiction of an embodiment of the de-nesting assembly.De-nesting finger 361 has a notch 365 cut in a distal end of the finger361. In one embodiment, the notch is V-shaped. De-nesting finger 362 hasan approximately vertical plate 366 extending from a distal end of thefinger 362. The vertical plate may be flat, curved to match the curve ofthe paper cone, or angular to approximate a curve. In one embodiment,the vertical plate is T-shaped. The notch 365 and vertical plate 366 arecalibrated such that the when the de-nesting fingers come together, thenotch and vertical plate sufficiently contact the cone so as tofrictionally engage the cone without causing plastic deformation of thecone. The de-nesting actuator 363 brings the de-nesting fingers togetherto engage the cone, and the vertical actuator 364 moves the de-nestingfingers vertically to extract the cone from the carousel 200. It shouldbe appreciated that while two actuators may be used, a single multi-axisactuator could also be used. The T-shape of the plate on de-nestingfinger 362 helps provide additional frictional surface area to helpengage the cone and prevent plastic deformation. In some embodiments,the de-nesting fingers may be coated with a frictional material, such assoft rubber or plastic, to increase the friction between the de-nestingfingers and the cone. In an alternate embodiment, the de-nesting fingersmay be replaced with a de-nesting suction cup such that the suction cupattaches to the cone by vacuum, the de-nesting assembly pulls the conedown, and then the vacuum is released detaching the suction cup from thede-nested cone.

In one embodiment, vertical actuator 364 moves the de-nesting fingers361, 362 to extract one cone while the packaging assembly simultaneouslyactivates hole actuator 260 on the second plate to open and allow thestack of cones to move vertically. Once the stack moves sufficientlyvertically downward (which can be determined, for example, based ontiming or sensor feedback), the hole actuator 260 engages the next coneto support the weight of the stack of cones, and the bottom conesufficiently engages (such as by friction) the geometric hole 236 tohold the remaining cones.

Thus, as one cone is removed from the bottom of the stack of cones 1100a, the hole actuator 260 temporarily releases pressure on the stack ofcones and allows the stack to lower by one cone. The hole actuator 260then reapplies pressure to the stack to prevent more than one cone fromexiting through the hole in the lower plate 230. Once all of the conesin one stack are pulled through the hole in the lower plate 230, the rodactuator 250 rotates the plates such that the next stack of cones (notshown) is in position to supply additional cones. In one embodiment, anempty sensor 367 identifies that a cone was not grasped by thede-nesting fingers as the de-nesting fingers come together completely,thus tripping the sensor. Upon receiving a signal from the empty sensor367, the control system may attempt to grasp a cone again. After one ormore failed attempts, the control system may determine that the stack ofcones 1100 a is depleted and send a signal to turn the carousel 200 andorient a new stack of cones over the de-nesting fingers beforeattempting to again grasp a cone.

The cones are extracted from the cone stack and deposited on the coneconveyor 300. As shown in FIGS. 3D and 3E, the cone conveyor includes adie-plate 301, dies 310, 320, 330, 340 (though it should be appreciatedthat while four dies are shown, more or less dies could be utilized), asupport shaft 302, and a cone conveyor actuator 303. The die-plate 301is mounted to support shaft 302. The cone conveyor actuator 303 rotatesthe support shaft and thereby rotates the die-plate 301 to convey thedies (and any cone a die contains) through the packaging assembly. Itshould be understood that the cone conveyor actuator could be adapted todrive the cone conveyor directly (such as by mounting directly to thedie-plate and thereby rotate the die-plate directly). In such anembodiment, the support shaft 302 may be unnecessary. However, in oneembodiment, the support shaft may be used to provide separation betweenthe die plate 301 and a mounting surface (such as a bench or table)(see, for example, FIG. 1 , table 101). It should be appreciated that alarger cone conveyor with more dies could be utilized, and even aflexible conveyor with many dies.

In one embodiment, the cone conveyor 300 may include multiple dies, andpreferably includes four dies 310, 320, 330, and 340. The dies may holda cone to be filled and allows a filled cone to be extracted from thedie. For explanatory purposes, an embodiment of a die is shown in FIGS.3F and 3G. The die may be made of two clamping segments 311 and 312(though more complex dies made of more clamping segments or analternative structure could be used). Clamping segment 311 has a contactsurface 311 a and a groove 311 b while clamping segment 312 has acontact surface 312 a and groove 312 b. When brought together, contactsurface 311 a mates with contact surface 312 a, and the grooves 311 band 312 b of the clamping segments define a cavity (see, generally 313)having a distal end 314 and a proximal end 315 that traverses thevertical thickness of the clamping segments. In some embodiments thevertical thickness of each clamping segment may be the same, but inother embodiments the vertical thickness of one clamping segment (forexample 311) may be different than the vertical thickness of the otherclamping segment. Preferably, the cavity 313 exhibits the shape of atruncated cone such that the diameter of the cavity is larger at thedistal end 314 and tapers toward the proximal end 315. A die actuator350 moves one or more of the segments to open and close the clampingsegments 311, 312, and thereby open and close cone shape cavity 313allowing a filled cone to be extracted from the die. In operation,de-nesting assembly 360 deposits a cone into cavity 313 of the die 320and the cone is held by the die. The cone is then filled, and dieactuator 350 may then separate the clamping segments 311 and 312 and thecone may pass through the die. That also may prevent the cone fromundergoing plastic deformation as could occur if the cone were forciblyremoved from the die, such as could happen from gripping the cone.

With respect to filling the cone, after the cone is deposited in thedie, the cone conveyor rotates and positions the cone beneath a packingstation 500 which, in one embodiment is associated with a hopper station400 (see FIGS. 1A and 1B). In one embodiment, the hopper stationincludes a conveyor 407. With reference to FIGS. 4A-4D, leaves (notshown) are fed into hopper 401 b. In one embodiment, as shown in FIG.4C, the hopper comprises a container that is generally athree-dimensional rectangle with four sides. It should be appreciatedthat the hopper could be a different shape, such as tubular withuniform, seamless sides. The hopper includes a hopper inlet 402 at thetop, through which leaves may be supplied, and a hopper outlet 403 atthe base to allow for leaves to exit the hopper. At the base of thehopper is a damper plate 404 that closes the base of the hopper outlet403 and prevents leaves from exiting. The hopper is preferably mountedproximally to the damper such that when the packaging apparatus is notin operation, there is a gap 405 between the hopper outlet 403 and thedamper plate 404. The hopper or damper plate or both may be adjustableto increase or decrease the gap between them depending on the size ofthe leaves. In one embodiment, the damper plate is connected to theinside of the conveyor 407 and is actuated by leaf conveyor actuator 408which moves with the conveyor and damper plate relative to the hopperand thereby meters out leaves from the base of the hopper.Alternatively, the damper plate could be mounted directly to an actuatorwhereby that actuator vibrates the damper plate relative to the hopperand thereby meters out leaves from the base of the hopper. It should beappreciated that the hopper could alternatively or additionally beconnected to an actuator to effectuate movement of the position of thehopper relative to the damper. In one embodiment, the damper plate ismounted to the conveyor 407 which is in-turn connected to a leafconveyor actuator 408 such that one actuator may be used to vibrate boththe damper plate 404 and the conveyor 407 simultaneously. In oneembodiment, the conveyor 407 is mounted to a base 409 by one or moreresilient mountings. For example, resilient mounting springs 410. Theresilient material assists in effectuating consistent vibration betweenthe conveyor and hopper. As noted, to assist in the flow of leaves outof the hopper, the damper plate or hopper may be adjustable such thatthe static distance of the gap between the damper plate and the hopperis variable. For products that have a very fine texture, that staticdistance may be set very small, but it may be increased when large grainproducts are being fed.

In one embodiment, the conveyor is substantially V-shaped and forms achannel that moves leaves along the length of the conveyor from adeposit end 412, where leaves are deposited by the hopper to an outputend 413, where the leaves are output to the packing station. In oneembodiment, the hopper 401 exhibits a tapering shape. For example, wherea box-shaped hopper is used, the hopper outlet 403 at the base of thehopper may be approximately 3 inches square while the hopper inlet 402at the top of the hopper may be approximately 2.5 inches square. Thatconfiguration is advantageous because it restricts the incoming flow ofleaves and allows the leaves to move from a lower volume space at thetop of the hopper to a larger volume space at the base of the hopper.That helps prevent clumping of the leaves in the hopper.

The hopper deposits leaves onto the leaf conveyor 407. In one embodimentthe leaf conveyor is constructed of a uniform piece of sheet metal thatis bent into a V-shape. While it is conceivable that other materialscould be used, the use of sheet metal helps prevent static buildup andthereby assists in consistent conveying of leaves. Forming the conveyorof a uniform sheet of material eliminates seams where leaves couldotherwise be caught. The V-shape helps create a uniform line of leavesand thereby maintains a consistent flow of leaves along the conveyor.That assists in reliable filling of the cones later in the process.Additionally, the sides of the conveyor may be wider apart at thedeposit end and then narrow as the conveyor approaches the output end.That allows leaves to easily be caught by the conveyor as they exit thehopper at the deposit end and form into a controlled line at the outputend of the conveyor.

Additionally, the conveyor is slightly upwardly angled in the conveyingdirection. That is, as leaves move along the conveyor away from thehopper, the leaves rise. A leaf conveyor actuator 408 is connected tothe conveyor. The actuator vibrates the conveyor to cause leaves to movealong the length of the conveyor. The combination of the vibrations andthe rise in the conveyor assists in creating a uniform line of leaveswithin the conveyor which leads to more consistent depositing of leavesinto the cones.

In one embodiment, as shown in FIG. 4D, a sensor 415 monitors the levelof the leaves moving along the conveyor and provides feedback to thecontrol system (for example via wire relay or wireless communication) toactivate an adjustment actuator 416 that adjusts the positioning of thehopper 401 with respect to the damper plate 404 thereby adjusting thegap 405 between the hopper and the plate to permit more or less leavesto exit the hopper. It should be appreciated that the adjustmentactuator could adjust the position of the hopper (while the damper plate404 remains fixed with respect to the conveyor), or the adjustmentactuator could adjust the position of the damper plate 404 (while theposition of the hopper remains fixed). The sensor may be a photoreceptorthat captures data relating to the height of the leaves moving along theconveyor. The sensor relays the data to the control system over asampling period, for example every 1 second, and the control systemdetermines whether the height of the leaves is within an acceptablerange. If it is out of range, for example too high (indicating too manyleaves are exiting the hopper), the control system may send a signal toan adjustment actuator causing the adjustment actuator to move andadjust the respective positioning of the hopper 401 and damper plate404. In one embodiment, the actuator is a linear actuator that moves toslide the hopper closer or further away from the plate. While theincrements of movement may vary, for general leaf based products, it hasbeen found that movement of the relative position of the hopper to thedamper in 0.1 mm increments tends to result in the optimal adjustment ofproduct flow.

In an alternate embodiment, an alternative hopper may be used inaddition to the conveyor 407 or even in place of the conveyor. As shownin FIGS. 4E and 4F, a grinder hopper assembly 450 may be utilized. Thegrinder hopper assembly 450 includes a hopper 401 a having a hopperinlet 402 and a hopper outlet 403. At the outlet of the hopper is awheel 451 that is operated by a wheel actuator 452. The wheel mayinclude a textured surface so as to function as a grinding wheel. In oneembodiment, the hopper funnels toward the hopper outlet 403, and theoutlet is approximately the same width as the wheel 451. A portion ofthe wheel fits within the hopper outlet so as to substantially block theflow of leaves out of the hopper while leaving a gap between a surfaceof the wheel and a portion of the hopper. The control system sends asignal to the wheel actuator to drive the wheel. When leaves are in thehopper, as the wheel spins it draws leaves through the gap between thewheel and the hopper. When a textured wheel is used, the spinning of thetextured wheel may grind the leaves as the leaves are forced between thesurface of the wheel and the hopper at the hopper outlet. As the leavesexit the outlet, they may be deposited into the conveyor 407, oralternatively deposited directly into a weigh station.

With reference to FIGS. 1A-1B and FIGS. 5A-5F, the packing station 500is associated with a weigh station 510, a chute 520 with chute inlet521, a chute exhaust port 530, a packer head 570, an outlet funnel 550with an exit hole 551, and a packing rod 541. In one embodiment, thepacking station includes an inlet funnel 501. The conveyor or grinderhopper deposits leaves into the weigh station 510. The weigh stationincludes a sensor for determining the proper amount of leaves. Anynumber of sensors could be used, such as optical, sonic, and contactsensors. It should be appreciated that the weigh station need notactually weigh the leaves. In one embodiment, the sensor is a contactsensor that senses the weight of the leaves. As shown in FIGS. 5E and5F, one or more sensors 511 are associated with the outlet doors 512,513 at the bottom of the weigh station (though a single outlet door ormultiple outlet doors could be utilized). The outlet doors areconfigured to open and close to allow leaves to build up in the weighstation and then be deposited in the packing station (such as throughthe chute 520 through chute inlet 521). In one embodiment, one or moresensors 511 send signals to the control station as the leaves aredeposited in the weigh station. In an embodiment utilizing the grinderhopper assembly 450, leaves may be deposited directly from the hopperoutlet 403 into the weigh station, the weigh station may send signals tothe control station indicating the weight of the leaves, and as theweight increases (or at preset weight thresholds stored in the controlsystem) the control system controls wheel actuator 452 to vary the speedof the wheel. For example, as the weight of leaves increases, thecontrol system slows the speed of the wheel to more accurately depositsmaller amounts of leaves to hit a target weight (which may be a presetvalue stored in the control system). When the proper amount of leavesfill the weigh station, and the control system signals one or more weighstation actuators 514 to open the outlet doors of the weigh station andrelease the leaves into chute 520. The control system may then increasethe speed of the wheel actuator (and wheel) to initially more rapidlyfill the weigh station. One or more actuators open outlet doors 512,513. The leaves fall down the chute 520 and into the packer head 570where they are deposited into an outlet funnel 550. The packer head isessentially a cavity that contains leaves from the chute in preparationfor filling a cone (though it should be understood that the chute andpacker head could be formed together as a unitary structure). In oneembodiment, see for example FIG. 1B, the hopper outlet 403 and a portionof the wheel 451 nest inside the weigh station 510 (see nesting cavity515 in FIG. 5E) so as to limit the possibility of leaves errantlyexiting the weigh station and preventing unwanted debris from enteringthe weigh station.

The chute, packer head, and outlet funnel may be formed separately andconnected together (such as by bolts or welding) or may be formed as anintegral unit, or a combination thereof. In one embodiment, the chute,packer head, and outlet funnel are sealed together (or formed together)to prevent leaves from spilling out. The packer head and outlet funnelmay also be connected to an actuator that moves the packer head andoutlet funnel up and down. In operation, the packer head begins in araised position, a die (for example, 310) holding a cone is movedbeneath the packer head, the packer head is then lowered onto the die.In some cases, the top of the cone may protrude from the top of the die.By moving the packer head, the die and cone may be moved into positionand the packer head can also move into position and if necessary pressthe cone into the die all without risk that the cone will be damaged.

In one embodiment, the packer head 570 and outlet funnel 550 are loweredonto the die to engage the top surface of the die such that leaves areprevented from traversing the junction between the bottom of the outletfunnel and the top of the die. In one embodiment, a cone support system560 (see FIGS. 5G-5I, and FIG. 6D). In one embodiment, the cone supportsystem includes a cone support 561 that is connected to an supportactuator 562. The support actuator 562 may further be connected to amounting bracket 563 and table mount 564 to fix the cone support systemto table 101. The support actuator 562 lifts the cone support 561 suchthat it may be moved to engage and disengage the proximal end of a conethat is within a die on the cone conveyor. In one embodiment, two conesupport systems are provided, such as in FIG. 5H with, for example, conesupport system 560 a being associated with the packing station 500 whilecone support system 560 b is associated with folding station 600.

In one embodiment, the cone support 561 is cup shaped with a cone bottomsurface 565 at the base, a raised side wall, a suction rim 567, and anexhaust port 568. The cone support may also include a grate 569 suchthat when the cone support is lifted to engage with a proximal end of acone, the grate separates the proximal end of the cone from the bottomsurface 565. When the die holding a cone is positioned under the packerhead 570, for example, the support actuator 562 moves the cone support561 such that the contact surface 565 (or grate 569) contacts theproximal end of the cone and adjusts the height of the cone within thedie. In one embodiment, a sensor, such as a pressure sensor, is used todetermine if the cone is at the proper height by registering resistanceof the cone due to the distal end of the cone pressing against thefunnel 550. In another embodiment, the height of the cone is a presetvalue, and the cone support moves to a preset height beneath the packerhead 570 to lift the cone to the proper height. The suction rim 567contacts the bottom of the die holding the cone. A vacuum tube may beconnected to the exhaust port 568. With the rim 567 contacting the die,the vacuum may create a suction within the cone support 561 and, withthe grate 569 lifting the proximal end of the cone, the vacuum may drawair through the cone to assist with packing of leaves within the cone.The vacuum may also collect leaves that may fail to properly enter thecone or that completely pass thought the cone.

The packer head is essentially an enclosed block (or container) thatprevents leaves from escaping the funnel. Referring to FIGS. 5C and 5D,the packer head also helps guide the packing rod 541. The packing rod isconnected to a packing rod actuator 542 that moves the packing rod 541within the packer head 570. Preferably, the packing rod is hollow andconnected to a pneumatic system that provides pressurized gas throughthe packing rod. The packer head 570 may also include an exhaust port531. Chute exhaust port 530 and exhaust port 531 may be connected to avacuum system that may selectively turn on and off to clear the chuteand packer head of leaves and keep the packing station free from abuildup of leaves.

In one embodiment, as leaves fall through the funnel 550 and out theexit hole 551 in the bottom of the funnel, the leaves are deposited intothe cone and a burst of pressurized gas is applied to pack the leavesinto the cone. The exit hole may be approximately the same size as thesize of the distal end of the cone. Also in one embodiment, the hollowpacking rod may be set to a static height, and the pressurized burstfunction operates the same. The packing rod may be set in a downposition such that it closes the hole in the bottom of the packer head.For example, the packing rod has an external circumference that isapproximately equal to the circumference of the exit hole 551 such thatthe packing rod may extend into the exit hole and substantially plug theexit hole. The actuator may slide the packing rod within the packer headand into and out of the exit hole to selectively plug and unplug theexit hole.

Leaves fall into the packer head and the packing rod in the downposition prevents the leaves from falling out early. Then a packing rodactuator 542 separates the packing rod 541 from the exit hole 551 in thebottom of the funnel 550. Leaves fall past the tip 540 of the packingrod 541 and through the exit hole 551 into the cone. The tip may behollow and communicate with the hollow packing rod to allow pressurizedgas to flow through the packing rod 541 and tip 540. While the tip maybe conical, alternative tips, such as flat, or rounded tips may be used.Successive pressurized bursts of gas are applied and, after each burstadditional leaves are permitted to fall past the tip of packing rod suchthat the pressurized burst pushed the leaves into the cone. The packingrod may be raised and lowered successively such that, when raised, someleaves to enter the cone, then the rod is lowed to stop the flow ofleaves while a burst of gas is applied, then the packing rod is raisedand the process is repeated.

In one embodiment, the packing rod actuator 542 and packing rod 541perform that process at least five times while the cone is being filledwith leaves. In one embodiment, the pressure of one or more of thebursts of pressurized gas may be varied. For example, the first burst ofpressurized gas may be applied at 60 psi, the second at 60 psi, thethird at 45 psi, the fourth at 30 psi and the fifth at 30 psi or less.For cones that are approximately 4 cm to 6 cm long, it was found thatthe preferable range of bursts is between 10 and 15 when utilizingsticky leaves, and optimally 12 bursts, varying the pressure between 60psi and 30 psi over the course of the application of bursts. Varying thepressure ensures that the leaves are uniformly packed within the cone.It also helps break apart any clumps of leaves that may have persistedfrom the conveying and weighing process. That too assists in ensuringthat the leaves are uniformly packed in the cone.

In embodiments utilizing air burst, the bottom portion of the packinghead funnel may be pressed into the top surface of the die so as tocreate a seal between the packer head and the die. In one embodiment,either the die top or the packer head bottom is equipped with a gasketto facilitate the seal. In operation, the packing rod is inserted intothe exit hole of the funnel and may seal the exit hole both to preventadditional leaves from falling through the exit hole and into the cone,and to prevent leaves within the cone from blowing back up through theexit hole when a burst of gas is applied to the cone. In one embodiment,the exterior surface of the packing rod may be resilient and permitelastic deformation of the exterior of the packing rod when insertedthrough the exit hole to facilitate a seal. In one embodiment thematerial forming the exit hole may permit elastic deformation of theexit hole when the packing rod is inserted into the exit hole.

After the cone is packed at the packing station, the cone may be movedto the folder station 600. With reference to FIGS. 6A-6P, the coneconveyor 300 rotates and thereby moves a die from the packing station500 to the folder station 600. The folder station includes a housing 601that accommodates a folding rod 602. In one embodiment, the folding rod602 is hollow and it guides an inner tube (or rod) 603 arranged withinfolding rod 602. A folder tip 604 is affixed to (or integrated with) adistal end of the folding rod 602, while a proximal end of the foldingrod 602 is associated with a folding rod actuator 610. In oneembodiment, an injector needle 605 may be arranged coaxially with thefolder tip 604 such that it may extend and retract from the folder tip604. In one embodiment, the inner tube 603 is connected at a distal endto the injector needle 605 (or the distal end of the inner tube may beintegrated with the injector needle) and the proximal end is connectedto a fluid transfer block 606 which is in turn connected to a fluidreservoir (not shown). The fluid transfer block 606 is connected to theinjector needle 605 by an inner tube 603 and may include a fluid hole607 that communicates with a fluid pathway (not shown) so as to allowfluid to flow from the fluid pathway into the fluid transfer block (andhence into the inner tube and injector needle) when the pathway andfluid hole are aligned, but also allow the fluid transfer block to slidewithin the housing. The fluid transfer block 606 may be located withinthe housing and include an actuator (not shown) that pumps fluid fromthe fluid reservoir through the inner tube 603 and out the needle 605,and may also extend and retract the needle 605 (alternatively anadditional actuator could be used to extend and retract the needle). Forexample, a pneumatic piston may be activated to apply pressure to thefluid transfer block and thereby force the fluid transfer block to pumpfluid through the needle. That allows a variable pressure to be appliedto the fluid transfer block, and by extension the fluid may be readilypumped out of the needle at a variable pressure.

The folder station 600 may further include a folding block 620. In oneembodiment, as shown in FIGS. 6A-6B, the folding block includes foursupport structures 621, 622, 623, and 624 each associated with a foldingfinger actuator 625, 626, 627, and 628, respectively, but it isconceivable that more or less support structures could be used. Eachsupport structure is connected to (or integrated with) a folding finger631, 632, 633, and 634. The connection could be accomplished throughfasteners, such as screws or rivets, or the connection could be made bywelding. Alternately the support structure and finger could beintegrally formed such that the support structure and finger areconnected into single unitary piece. The support structures surround thefolding block 620 having a cavity 629 extending vertically through itsuch that the cavity accommodates the folding tip and folding rod.

In one embodiment, the support structures are mounted to the foldingblock by one or more guide posts. In one embodiment, each supportstructure is mounted using two guide posts. For example, supportstructure 623 is mounted by guide posts 635 and 636. The folding fingeractuators 625, 626, 627, and 628 move the support structures and fingersalong the guide posts. It is conceivable that the guide posts could beeliminated and the actuators could be solely responsible for guiding thesupport structures.

In one embodiment, each folding finger has a distal edge with a recessformed in the distal edge. For example, folding finger 633 includesrecess 637. When the folding finger actuators move the supportstructures close to the folding block 620, the folding fingers are movedcloser to one another and the recess of each finger engage the topportion of the cone and cause the top of the cone to deform. Thatpre-folds the distal end of the cone. Preferably, the fingers are offsetsuch that they slide over one another such that the recesses of opposingfingers (i.e. fingers 633 and 631) are aligned when the fingers cometogether. One or more of the folding finger actuators may be actuated tomove the folding fingers together and apart from one another. In oneembodiment, the support structures are of approximately the same sizeand the guide posts are offset to ensure proper offset of the fingers.However, it is conceivable that the support structures could be made ofdifferent sizes or the mounting location could be altered to ensure theproper offset.

In one embodiment, only two folding fingers are utilized. With referenceto FIGS. 6I-6J, one embodiment includes folding block 620, supportstructures 641, 651, folding fingers 642, 652, and folding fingeractuators 643, 653. The folding fingers each include a recess 644, 654.In a further embodiment, recesses 644 and 654 are substantiallyV-shaped. For example, the recess 644 has a first side wall 660 and asecond side wall 661 that converge at a vertex 662. In one embodiment,rather than the sidewalls converging at a sharp, angular vertex to formthe V, the walls converge at a concavity, such that the walls of recess654 converge at concavity 655, and the walls of recess 644 converge atconcavity 645. Preferably, each concavity is semicircular. The concavityensures that when finger 642 and finger 652 come together (for examplefinger 642 is positioned to slide over finger 652 such that recess 644partially eclipses recess 654) a fold hole 663 remains between finger642 and finger 652. The fold hole 663 may accommodate a portion of thecone. Preferably, the hole is approximately 0.125 inches in diameter.The combination of the V-shaped recesses and the hole ensures that eachcone pre-folds together in substantially the same manner. The preferreddiameter of the hole keeps the pre-folded cone packed tightly togetherand enhances the uniformity of the button fold made by the folding tip.

With reference to FIGS. 6D-6G, (which depict an embodiment of thefolding station executing an example of a folding process and fluidinjecting process) in one embodiment, a die 310, containing filled cone1120 is moved below the folding station 600. In one embodiment, a conesupport 561 supports the proximal end of filled cone 1120. The conesupport may be integrated with or connected to support actuator 562 thatretracts when the cone conveyor 300 is rotating, and raises to contact(and in some embodiments lift) the filled cone 1120 when the coneconveyor is stationary. The lifting and retracting of the filled cone1120 can assist in ensuring that the distal end of the cone 1102protrudes from the die 310 for proper folding, but allows the distal endof the cone to be below the folding fingers when the cone conveyor isrotating. In one embodiment, the cone support may attach to the cone(such as through suction or mechanical clamping). Folding fingeractuators 643, 653 push the support structures toward the folding block620 and the recess of each finger engage the distal end of the filledcone 1120 and cause the distal end of the cone to deform (see generally690) and pre-fold the cone, folding rod actuator 610 causes the foldingtip 604 to contact the pre-folded top of the cone as shown in FIG. 6E.In one embodiment the top of the cone is partially drawn down throughthe recesses of the fingers as the fingers close and deform the top ofthe cone. For example, the cone support attaches to the proximal end ofthe cone by vacuum, and the support actuator 562 retracts to draw thecone down. Drawing the cone through the fingers creases the paper toenhance the pre-fold of the top of the cone. The folder tip 604 islowered onto the pre-folded cone. The fingers are retracted as thefolding tip is pressed into the distal end of the cone. That presses thefilled cone 1120 into the die 310 and completes the fold. In oneembodiment, the pressure of the folding tip on the cone creates a buttonfold.

With reference to FIGS. 6I, and 6L-6P, there is depicted an embodimentof a folder tip 670 and a both a perspective view of a filled, foldedcone and a cross-sectional view of a distal end of a filled, folded cone1120. In one embodiment, the fold hole 663 is approximately the sameshape and size as an axial pin 671 of a folding tip 670, such that thefingers 652, 642 may come together and press the paper of the coneagainst the axial pin 671. As the folding tip 670 presses into thedistal end of the filled cone 1120, the axial pin 671 prevents the conefrom fully enclosing the distal end, and when the folding tip isretracted, an access hole 1122 is formed in the folded paper 1121 of thefilled cone 1120.

In one embodiment, the folding tip 670 includes and exteriorcircumferential surface 672, an interior circumferential surface 673, anaxial pin 671, and a contact edge 674 as shown in FIGS. 6L-6N.Preferably the cross-section of the folding tip is circular, andpreferably the diameter of the contact edge 674 is less than the largestdiameter of the distal end of filled cone 1120. The exteriorcircumferential surface 672 of the folding tip 670 may be conical suchthat the angle α mates against the angle of the surface 316 of cavity313 of a die (for example die 310). The interior surface may also beconical. Preferably, the angle β of the interior surface is between 80°and 85°. The interior circumferential surface terminates at the axialpin and contact edge, respectively. During the folding process, thefolding tip may be placed at the distal end of the filled cone 1120 suchthat the axial pin 671 is below the rim 1103 of the distal end 1102 offilled cone 1120. As the fingers 642 and 652 converge, the axial pinprevents the fingers from completely collapsing the paper of the cone,and the paper of the cone is pressed against the axial pin. The foldingtip 670 is pressed toward the filled cone 1120 such that the paper ofthe distal end of the cone slides up the axial pin and is bounded by theinterior circumferential surface 673. The contact edge 674 presses thepaper of the cone into the leaves within the cone, crimping the paper ofthe cone in on itself (see generally, fold lines 1130 of the foldedportion of the cone (1121) and into the cone while the axial pinprevents the paper of the cone from completely covering the leaves. Inthis way, a portion of the paper of the cone is pushed into the interiorof the cone, while a portion of the paper cone protrudes beyond thelevel of the leaves 1140 (and any fluid 1124 where the filled cone isinjected with fluid) creating a circumferential lip 1123 around thecone. Also in this way, the end of the cone is folded to prevent theescape of leaves while leaving a small hole 1122 in the end of the cone.Thus, as shown in FIGS. 6O-6P the filled cone 1120 has a proximal end1101 (mouth) and a distal end 1102 (tip), a circumferential lip of paper1123, folded paper 1121 inside the circumferential lip, and an accesshole 1122, approximately in the center of the folded paper 1121 suchthat the rim 1103 of the filled cone 1120 is folded down and in towardthe center of the diameter of the cone.

In one embodiment, the length of an unfolded cone is betweenapproximately 4 inches and 4.5 inches in length. It was found thatfolding the distal end of the cone such that the folded portion pressedand contacted the leaves inside the cone was better suited to ensuringthat leaves within the cone did not freely pour out of the cone when thecone was inverted (particularly in folded cones having an access hole1122) and it improved lighting the distal end of the cone as opposed toleaving an air gap between the leaves in the cone and the folded paper.Additionally, it was found that folding the cone such that thecircumferential lip 1123 extended between approximately 2 mm and 5 mmproduced optimal results while maximizing the interior volume of thecone that could be filled with leaves.

A number of benefits were found when folding the tip of the cone toprovide the access hole 1122 in the distal end of the cone as well ascreating a circumferential lip of paper 1123 as opposed to completelysealing the cone either by a full button fold or by twisting the paperof the cone closed. One benefit is that the hole provides an accesspoint for a needle that can then be inserted into the cone to fill thecone with a fluid core but without having the needle pierce throughlayers of cone paper. It was found that attempting to pierce through thelayers of paper often displaced the leaves within the cone, or lead touneven compacting of the leaves which detrimentally affected the burningof the cone. The hole ensures that the needle does not meet excessresistance from the paper, and is able to penetrate the length of thecone, through the leaves, without unnecessarily compacting the leaves orcausing the paper to push into and displace the leaves at the top of thecone.

Additionally, the hole allows for the creation airflow through the conewhen lighting the filled cone. As a flame is brought proximate to thefilled cone, air may be drawn through the cone by creating a vacuum atthe small diameter end of the cone, thereby drawing the flame into thecone to contact the leaves and core. That assists in lighting the centerof the cone where the fluid core was deposited. Without the hole, whenthe tip is closed due to a complete fold or twisting closed of thepaper, it is difficult to create a vacuum in the unlit cone. When aflame contacts a completely closed tip, it was found that the flamewould light the paper, and then migrate, or run, down the side of thecone burning the paper rather than the leaves. While the leaves wouldeventually light, the run of flame tended to cause uneven lighting ofthe leaves (e.g. lighting the leaves in the vicinity of the run, ratherthan uniformly across the diameter of the cone) which contributed to anuneven burn rate for the filled cone. It also meant that the leavesalong the outside of the cone (proximate to the paper) would ignitedfirst, leaving the fluid filled core unlit. By adding the hole to thetip of the folded cone, when a vacuum is applied to the cone (drawingair in from the distal end and out through the proximal end), the flameis drawn directly into the center of the cone and into the fluid core,to (particularly where the fluid is a flammable oil) reliably light thecore and centrally located leaves. That results in burning away of thefolded paper first (before the paper of the cone surrounding and holdingthe leaves), which in turn helps contain the leaves as the cone burns,and it contributes more uniformly lighting and progressive burning ofthe leaves. It was found that providing a folding tip with the foregoingstructure created more reliably uniform folds in the end of the filledcone and simultaneously provided an airflow hole in the paper cone.

Additionally, it was found that even with the access hole, leaves withinthe cone would not consistently uniformly light, and there was risk offlame running down the length of the cone. However, by forming thecircumferential lip of paper, as the flame is drawn into the conethrough the access hole, it lights the more flammable circumferentiallip of paper concurrently. That is, the circumferential lip of paperprovides a mass of material, more flammable than the leaves and whichmass of material surrounds the distal end of the cone such that thepaper lights the circumference of the distal end and forms a strong,uniform cherry at distal end while preventing flame from running downthe side of the cone.

In one embodiment, after the cone is folded but while the folding tipremains proximal to the folded top of the cone, injector needle 605 maybe extended into the cone, either piercing the folded top or, when thepreferred folding tip with axial pin is used to fold the top, passingthrough the hole formed around the axial pin. The injector needle may beformed coaxially with the folding tip and extend through the foldingtip. With reference to FIGS. 6F-6G, the injector needle 605 is insertedinto the distal end of leaf filled, folded, cone 1120. Generally, it hasbeen found that inserting the needle approximately 80% of the length ofthe cone yields optimal results. Inserting the needle too far results influid placement too close to the proximal end, and can cause fluid tooversaturate the proximal end of the cone. If the fluid is not insertedfar enough, then the benefits of the fluid are not fully appreciated asthe product is used. In FIG. 6G, the injector needle 605 is extracted,and as the needle is extracted, a fluid 1124, such as an oil, isextruded from the needle and into the filled cone 1120. In oneembodiment an actuator applies variable pressure such to extrude avariable amount of fluid as the needle is extracted. Preferable lesspressure toward the distal end of filled cone 1120, with increasingpressure as the needle is further extracted and progresses toward thedistal end of filled cone 1120. When a tapered cone is being injectedwith fluid, this allows less fluid to be deposited toward the proximalend of the cone where the cone is narrower and more fluid to bedeposited toward the thicker distal end of the cone.

In one embodiment, after folding is complete, (and in some embodimentsafter any desired fluid is injected and the needle retracted) the coneconveyor 300 moves the die with the filled, folded cone to a qualitycontrol station 800. For example, the cone conveyor 300 rotates the die310 holding the filled, folded cone to the quality control station anddie actuator 350 separates clamping segments 311, 312 of die 310 andreleases the cone. In one embodiment, a cleaning actuator inserts acleaning brush into the cavity 313 of the die to ensure that the filledcone is released and to clean the hole in the die. This helps preventresidue from building up within the die which may otherwise cause conesto stick within the die. The cone may be deposited on a quality controlhopper 801.

With reference to FIG. 8 , in one embodiment, a quality control stationincludes one or more sensors that check attributes of the filled coneagainst preset values stored in the control system and determine whetherthe filled cone is acceptable. For example, one or more sensors, such asa camera or scale may analyze the shape or weight of the cone. In oneembodiment, the quality control hopper 801 of the quality controlstation temporarily holds the filled cone for inspection by at least onequality control sensor (such as 804) and includes an exit chute 805. Ifthe attributes of the cone fall within an acceptable tolerance, the coneis accepted. The cone may be released from the quality control hopper801 to the exit chute where diverting arm 807 may direct the cone to aconveyor 806 (alternately, the cone may be directed to a packagingcontainer or placed in a sealable package). If the attributes of thecone do not fall within an acceptable tolerance, a diverting arm 807 maybe moved by an arm actuator 808 to block the cone from the conveyor. Thediverting arm diverts the cone into a reject bin 809. The diverting armactuator 808 then moves the diverting arm 807 to allow subsequent conesto be deposited onto the conveyor. In another embodiment, the exit chute805 temporarily holds the filled cone for a further inspection, such asan optical inspection by optical sensors. The cone may then be sent to aconveyor 806 that accommodates the filled cones and allows for furtherinspection, or, in alternative embodiments, moves the cones for furtherprocessing such as core filling. Filled cones may then be accepted orrejected and sent from the conveyor 806 to sealable package containersor the reject bin.

As noted, after an initial quality control check of the cones that arefilled with leaves and folded (or in some embodiments without anyquality control step, but simply after the cones are filled and folded),the cones are moved by a conveyor, for example conveyor 806, to aninjector station 700. In such embodiments, the injector needle may bearranged as a separate core injector station.

FIGS. 7A-7D depict various aspects of an embodiment of a separateinjector station 700. As shown in FIG. 1A, an injector station 700, isarranged apart from the folding station 600 of the packaging system. Inone embodiment, filled cones 1120 are transported to a receptacle 701 byconveyor 806. For example, a conveyor 806 transports the filled conesand deposits each cone in the receptacle 701. A receptacle actuator 702may adjust the positioning of the receptacle with respect to theconveyor, such as by tilting it back and forth, to ensure that the coneis deposited properly. In one embodiment, after the cone is deposited, apositioning actuator 703 adjusts the positioning of the receptacle withrespect to an injector needle 605, such as be sliding the receptaclecloser to the needle 605. It should be understood that the needle couldalternatively be moved closer to the receptacle, or both could be movedto converge with one another. Also, in place of a receptacle actuatorand a positioning actuator, a single multi-axis actuator could beutilized. In a further embodiment, a robotic arm manipulates theposition of the receptacle with respect to the conveyor (so that conesfrom the conveyor are deposited in the receptacle) and the fillingstation. The robotic arm may further move the receptacle from thefilling station to a packaging station 770 where the cone may be placedin a sealable package and, in one embodiment, the sealable package maybe purged with an inert gas and sealed. Alternatively another conveyorcould be used to move filled cones from the injector station to thepackaging station.

The injecting station may further include a needle slide 704, fluidcircuit 720, fluid pump 731, one or more heating elements 740, and afluid reservoir 750. The injector station may further include one ormore pressure sensors (which may be integrated with valve actuators)that sense the fluid pressure within the fluid circuit. The injectorstation may further be equipped with valves, e.g. 761 a, 762 a and valveactuators, e.g. 761 b, 762 b, for actuating the valves to alter the flowof fluid within the fluid circuit. The injector needle 605 is hollow andis positioned coaxially with the needle slide 704. In one embodiment,the needle slide is also hollow, and includes an access port 705 alongits length. The access port is in fluid communication with the hollowneedle, such that fluid flowing through the access port may exit throughan end of the injector needle 605. A needle actuator 710, moves theneedle slide within the fluid circuit such that fluid may flow throughthe access port while the needle slide (and needle) move. Fluid flowsthrough the fluid circuit and into needle slide through the access port705 and then out through the needle 640. To control the flow of fluid,the fluid pump 731 operates to pump fluid from the reservoir into thefluid circuit. Working in conjunction with the valves, the fluid pumpdraws fluid from the reservoir into the fluid circuit by applyingnegative pressure to the fluid circuit (including the fluid reservoir750), the fluid pump then applies positive pressure to the fluid circuitto force fluid to flow through the access port 705 and thus through theneedle as the needle is retracted from the cone, thereby depositing acore of fluid within the cone. Just prior to the needle exiting the topof the cone, for example while 0.5 cm of the needle remains within thecone, the fluid pump 731 (which may work in conjunction with thevalves), stops applying positive pressure to the fluid circuit andinstead applies negative pressure to the fluid circuit therebyretracting fluid back up the needle (thereby preventing fluid fromleaking out of the tip of the needle) and again drawing fluid out of thereservoir. The core-filled cone may then be removed from the receptacle,transferred and deposited in a second quality control station, thestructure of which is similar to the quality control station 800, or maybe sent to a packaging station 770 and sealed in a package.

To enhance the accuracy of the core filling, heating elements 741, 742,743, 744, and 745 maintain proper temperature of the fluid within thefluid circuit and reservoir, thereby maintaining consistent viscosity offluid. One or more sensors may monitor the temperature, and feedbacktemperature data to the control system. Additionally, pressure sensors(which may be integrated with the valves, or alternatively pressure datamay be derived from the operation of the fluid pump) may transmitpressure data respecting the pressure of the fluid within the fluidcircuit. By correlating one or more of the pressure data and temperaturedata with data respecting inherent properties of the fluid being pumped(where data respecting such inherent properties are stored in thecontrol system) the control system determines the appropriate control ofthe pressure pump 731 to apply the correct pressure during the conefilling injection to ensure a uniform core fill in each cone.

While each process in the packaging assembly may be conducted separatelyand independently, they may also be combined and used together to form afilled cone. In one embodiment, the control system operates theactuators to successively perform operation on successive cones. Thefollowing is an example of the control system operating to fill a singlecone and is described in connection with the flowchart of FIG. 9 . Thefollowing description is of an embodiment that includes leaves within inthe hopper 401, and where at least one stack of cones is deposited incarousel 200 (though it should be understood that more or less conescould be present). It should also be understood that while the steps arerecited separately for explanatory purposes, various steps may beperformed simultaneously. More or less steps could also be utilizeddepending on the configuration of the packaging system and the desiredoutput product.

In the process at 901, the rod actuator 250 rotates the carousel 200with a cone stack 1100 a to orient a cone 1100 above a die 310. At 902the hole actuator 260 temporarily releases support of the cone stack1100 a and a cone is forced through the hole 236 into the die 310 andthe hole actuator 260 reengages the cone stack. At 903, de-nestingfingers 361, 362 may grip cone 1100 and assist in forcing it throughhole 236. The sensor 367 of the de-nesting fingers determines if a coneis gripped 903 a. If no cone is gripped 903 c, the sensor 367 sends asignal to the control system. The system will attempt to grab a conethree times 903 d. If it is not the third try 903 e, the de-nestingfingers will try to grab a cone again. If it is the third try 903 f thecontrol system will rotate the carousel (see 901) to move a new stack ofcones into alignment and attempt the process again. If no signal is sent903 b, indicating a cone was grabbed and deposited into the cone die,then at 904 cone conveyor actuator 303 moves the cone conveyor 300 andthe die 310 into position underneath the packer head 570 and funnel 550,aligning the open distal end of the cone with the exit hole 551 in thefunnel 550. At 905 cone support actuator 562 raises the cone support 561and cone 1100 to the proper height and packer head 570 with funnel 550may be lowered onto the die 310. At 906 the leaves are deposited intothe weigh station 510. The weigh station sensor 511 sends a signal tothe control system indicating, for example, the weight of the leaves.The control system assess whether the weight is within tolerance 906 a,such as by checking the sensor signal against a preset value stored inmemory, if it is not, the sensor continues to check the weight as leavesare added. If it is 906 b, then at 907 one or more weigh stationactuators 514 move the outlet doors 512, 513 to drop the leaves into thepacker head 570 and funnel 550. As the leaves fall through the funneland into the cone, at 908, the packing rod successively applies burstsof pressurized gas. At 909 cone conveyor actuator 303 moves the coneconveyor 300 and the die 310 into position underneath the folder station600 and aligns the cone with the folder tip 604 as vacuum removes excessleaves in the packer head. At 910, support actuator 562 raises conesupport 561 and filled cone 1120. At 911 the actuators 643, 653 move thefolding fingers 642, 652 toward the folding block 620 and the foldingtip 604 descends onto the distal end of the cone. At 912, the foldingfingers 642, 652 pre-fold the distal end of the cone and the cone isdrawn through the fingers. At 913, the folding rod actuator 610 forcesthe folding tip 604 into the top of the pre-folded cone, and the foldertip presses the top of the pre-folded cone into the die 310 to completethe fold of the distal end of the cone. At 913, injector needle 605 isinserted into the cone. At 914, the needle is withdrawn as fluid isinjected into the leaf filled cone. At 915 the cone conveyor 300 rotatesand moves the die 310 to the quality control station and deposits thecone in the quality control hopper 801. At 916 sensors determine if thefilled cone meets proper specification 916 a. If it is within tolerance916 b, the filled cone is diverted 917 a to an acceptance conveyor. Ifit is not 916 c, the cone is diverted 917 b to a reject bin. In analternate embodiment, the needle and filling steps (913, 914) may occurafter the quality control steps (916, 917), and in some embodiments thequality control steps (916, 917) may be repeated multiple times for asingle cone. Also with respect to the pumping of fluid into the cone,the control system may monitor the temperature and pressure of the fluidand adjust the temperature, pressure, or both based on empirical data tomaintain consistent flow through the needle and into the cone.

FIG. 10 is a schematic of an embodiment of a control system that isconfigured to control the various assemblies of the packaging apparatus.It includes a main controller 1000 having a memory 1001, input/output1002, and a CPU 1003. The I/O 1002 may be connected to one or more I/Odevices 1005 such as a display, keyboard, mouse, touchscreen, etc. Thevarious actuators of the system may be connected to the main controller.It should be understood that the main controller could be a singlecomputer that handles all of the signal processing or multiple computersnetworked together and may further include hardwired circuit controllersas well. The main controller sends signals to the actuators of thesystem to control the operation of the actuators. For pneumaticactuators, the main controller may be connected to a series of valvesand actuate valves associated with the actuators to cause the actuatorsto actuate. It should also be understood that the actuators (forexample, in the case of the use of a servo motor) may send feedbacksignals to the main controller which the main controller may use tofurther control the operation of the actuators or the actuators may beequipped with additional sensors to monitor their operation and sendfeedback to the main controller. The sensors of the system may also beconnected to the main controller and send feedback to the maincontroller which the main controller may use to control the operation ofone or more actuators. The heating elements, such as heating element740, may be connected to and controlled by the main controller. Theheating elements may further include sensors that sense the temperatureof the heating elements and send feedback signals to the main controllerregarding the operation of the heating elements that the main controllermay use to adjust the temperature.

Although the present invention has been described in terms of variousembodiments, it is to be understood that such disclosure is not intendedto be limiting. Various alterations and modifications will be readilyapparent to those of skill in the art. For example, while theembodiments shown depict the various components in static arrangement,it is contemplated that each could be structured in a dynamicarrangement such that processes such as depositing cones on the coneconveyor, packing the cones, and injecting the cones occur with thestations moving relative to one another, but remaining stationaryrelative to the cones. Accordingly, it is intended that the appendedclaims be interpreted as covering all alterations and modifications asfall within the spirit and scope of the invention.

What is claimed is:
 1. A method of forming a folded package having aninterior cavity at least partially defined by a circumferential distalrim of a distal end of a paper cone comprising: orienting the paper conehaving a proximal end and the distal end in axial alignment with afolding tip such that the distal end of the paper cone is closer to thefolding tip than the proximal end, the paper cone further comprising astructure that permits air to flow into the interior cavity through thedistal end and out through the proximal end; applying vacuum pressure tothe paper cone; using the folding tip to apply a force to the distal endto press the folding tip and distal end together so as to fold thedistal rim of the distal end of the paper cone into the interior cavity.2. The method of claim 1 further comprising: continuing the applicationof vacuum pressure to the paper cone as the distal end and folding tipare forced together.
 3. The method of claim 1, wherein the direction ofthe force applied by the folding tip is parallel to an axis of the papercone that is in axial alignment with the folding tip.
 4. The method ofclaim 1 further comprising: after orienting the paper cone in axialalignment with the folding tip, arranging the folding tip such that aportion of the folding tip surrounds the distal rim of the distal end ofthe paper cone; and applying a vacuum to the paper cone.
 5. The methodof claim 1 further comprising: heating a substance to the melting pointsuch the substance is fluid; inserting a needle into the folded package;injecting the substance into the folded package through the needle. 6.The method of claim 1 further comprising: after orienting the paper conein axial alignment with a folding tip, applying a first force in theform of mechanical pressure to the exterior of the distal end of thecone so as to compress a least a portion of the distal end of thepackage toward an axis of the paper cone that is in axial alignment withthe folding tip; releasing the first force; and applying a vacuum to thepaper cone.
 7. The method of claim 1, wherein the folding tip includes acontact edge and an axial pin that extends along a central axis of thefolding tip, the method further comprising: orienting the paper cone inaxial alignment with the central axis of the folding tip; thereafter,applying a first force to the distal end of the paper cone that is in adirection that is not parallel to the central axis to compress thedistal end against the axial pin; and releasing the first force asfolding tip applies the force to the distal end such that the forceapplied to the distal end is applied in a direction that is parallel tothe central axis.
 8. The method of forming the folded package of claim 1further comprising: heating a substance to the melting point such thesubstance is fluid; inserting a needle into the folded package;injecting the substance into the folded package through the needle.
 9. Amethod of forming a folded package having an interior cavity at leastpartially defined by a circumferential distal rim of a distal end of apaper cone comprising: orienting the paper cone in axial alignment witha folding tip; adding particulate matter to the interior cavity;applying positive air pressure to the interior cavity through the distalend; using the folding tip to apply a force to the a distal end ofpackage together so as to fold a distal rim of the distal end of thepackage into the interior cavity.
 10. The method of claim 9, wherein theforce applied by the folding tip is applied in a direction that isparallel to an axis of the paper cone that is in axial alignment withthe folding tip.
 11. The method of claim 9, further comprising: applyinga force to the distal end in a direction that is not parallel to an axisof the paper cone that is in axial alignment with the folding tip. 12.The method of claim 9 further comprising: heating a substance to themelting point such the substance is fluid; inserting a needle into thefolded package; injecting the substance into the folded package throughthe needle.
 13. The method of claim 9 further wherein the folding tipincludes a contact edge and an axial pin that extends beyond the contactedge, the method further comprising: after orienting the package inaxial alignment with a folding tip, applying a first force to the distalend of the paper cone to compress the distal end against the axial pin;and releasing the first force as folding tip to applies the force to thedistal end.
 14. A method of forming a folded package having an interiorcavity at least partially defined by a circumferential distal rim of adistal end comprising: orienting the package in axial alignment with afolding tip; applying vacuum pressure to the exterior of the package;depositing particulate matter to the interior of the cavity; applyingpositive air pressure to the interior cavity through the distal end tocompress the particulate matter within the interior of the cavity; usingthe folding tip to apply a force to the distal end of the package so asto fold the distal rim of the distal end of the package into theinterior cavity.
 15. The method of claim 14, wherein the force appliedby the folding tip is applied in a direction that it parallel to an axisof the package that is in axial alignment with the folding tip.
 16. Themethod of claim 14 further comprising: after orienting the package inaxial alignment with a folding tip, arranging the folding tip such thata portion of the folding tip surrounds the distal rim of package andsuch that a central portion of the folding tip is below the distal rimof the distal end of the package and within the interior cavity.
 17. Themethod of claim 16 further comprising: Applying a first force to thedistal end of the package in a direction that is not parallel to theaxial alignment to compress the distal end of the package against thecentral portion of the folding tip.
 18. The method of claim 17 furthercomprising: Releasing the first force as the folding tip applies theforce to the distal end of the package.
 19. The method of claim 14further comprising heating a substance such that the substance is fluid;inserting a needle into the folded package; injecting the substance intothe folded package through the needle such that the package contains acore of the substance extending along the axis of the package.